Load supporting structures haying
auxiliary mounting frame means



Se t. 8, 1970 E. T. GETZ ETAL Re. 26,947

LOAD SUPPORTING STRUCTURES HAVING AUXILIARY mouu'rms FRAME MEANSOriginal Filed Aug. :5, 1966 5 Sheets-Sheet l INVENTORS EDWARD T. 6572'MATTHEW PAC/1K ATTORNEYS Sept. 8, 1970 E GETZ ETAL Re. 26,941

LOAD SUPPORTING STRUCTURES HAVING AUXILIARY MOUNTING FRAME MEANSOriginal Filed Aug. 3, 1966 5 Sheets-Sheet I W In in INVENTORS EDWARD T.GETZ ATTORNEYS Sept. 8, 1970 1', 351-2 EI'AL Re. 26,947

LOAD SUPPORTING STRUCTURES HAVING AUXILIARY MOUNTING FRAME MEANSOriginal F'ilecl Aug. :5. 1966 3 Sheets-Sheet 5 INVENTORS EDWARD I GETZMATTHEW PACAK ATTORNEYS United States Patent 26,947 LOAD SUPPORTINGSTRUCTURES HAVING AUXILIARY MOUNTING FRAME MEANS Edward T. Getz,Cleveland Heights, and Matthew Pacak, Solon, Ohio, assignors to EatonYale & Towne Inc., Cleveland, Ohio, a corporation of Ohio Original No.3,363,943, dated Jan. 16, 1968, Ser. No. 569,872, Aug. 3, 1966.Application for reissue Feb. 4, 1969, Ser. No. 813,773

Int. Cl. A47c 27/14, 27/22 US. Cl. 297-452 21 Claims Matter enclosed inheavy brackets appears in the original patent but forms no part of thisreissue specification; matter printed in italics indicates the additionsmade by reissue.

This invention relates to load supporting structures adaptable for useas vehicle seats and backs, furniture, crash pads, etc., or othercushion devices of this general nature. More specifically, thisinvention is directed to a composite load supporting structure includinga unique internal frame reinforcement assembly and resilient materialcombined in a manner to provide a new and novel improved load supportingstructure.

In the prior art, cushions or other seat constructions used as loadsupporting structures of this general type, did not take maximumadvantage of the combination of the internal support structure andresilient material makup the cushion or seat. The spring or otherinternal reinforcement structure common in prior art structures n wereexpensive and cumbersome and difficult to assemble. The springs ormounting structure were often covered and segregated from the resilientmaterial providing the requisite softness for the structure. The priorart foamed cushion units were usually covered with appropriate coveringmaterial which had to be secured by a costly and time consuming methodin which cover tie-down lines were threaded through the bottom portionof the structure to specially provided means on the bottom of the cover.The above discussed prior art structures were costly, complicated andincompatible with effective mass production requirements.

It is, accordingly, a major object of the present invention to provide aload supporting structure utilizing internal support means and foamedelastomeric material combined in a novel manner providing unexpecteddurability.

It is another object of the present invention to provide a loadsupporting structure of simple construction including a novelarrangement of foamed resilient material and cooperating internalsupport structure to which internal load transfer means and externalcovering material can readily be united.

Another object of the present invention is to provide a structurereadily adaptable to any desired shape or size including internal framemeans supporting centrally extending load transfer means, andelastomeric material surrounding said frame means.

Another important object of this invention is to provide a loadsupporting structure as noted in the next preceding paragraph whereinthe load transfer means is composed of cantilevered mounted elementswhich extend into the area of greatest load on said structure forcooperatively transferring the load on said structure to said frame.

It is another object of the present invention to provide a loadsupporting structure of relatively simple construction includinginternal frame means and foamed elastomeric material having a moldedcontoured surface conforming to the desired shape of the load supportingstructure and covered by appropriate material secured in place to aportion of said frame.

Re. 26,947 Reissued Sept. 8, 1970 Another prime object of the presentinvention is to provide a unique internal frame and load transferarrangement to be molded within foamed resilient material wherein isprovided a rigid subframe having a bolster frame and mounting framesecured thereto with load transfer means secured to said mounting frameand extending in the central area of said structure.

Still further objects of this invention will become apparent upon areading of the following detailed description of the present inventionand annexed drawings in which:

FIGURE 1 is a perspective view of one embodiment of the load supportingstructures of this invention in the form of a seat showing the base andback portions in section with parts broken away to illustrate theinternal construction of the seat.

FIGURE 2 is a perspective view of the load supporting structure of thebase portion of the seat shown in FIG- URE 1.

FIGURE 3 is a plan view of the load supporting structure of FIGURE 2.

FIGURE 4 is a perspective view of a modified form of a load supportingstructure for a seat base.

FIGURE 5 is a front elevational view of the load supporting structurefor the seat back shown in FIGURE 1.

FIGURE 6 is a front elevational view of a modified form of loadsupporting structure for a seat back.

FIGURE 7 is a front elevational view of another modified form of a loadsupporting structure for a seat back.

Before explaining the present invention in detail, it is to beunderstood that the present invention is not limited in its applicationto the particular construction and arrangement of parts illustrated inthe accompanying drawings since the invention is capable of otherembodiments and of being practiced and carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein is for the purpose of description only and not oflimitations.

Referring to the drawings, FIGURE 1 illustrates an embodiment of thisinvention for a new and novel load supporting construction, andparticularly, illustrates a bucket type seat for use in vehicles. Itwill be obvious that the present invention is applicable to othervehicular seat constructions and forms and in other uses andconstructions as household and office furniture, crash pads, benches,etc.

While the structures illustrated are simple, flexible and economicaldesigns, it has been found through extensive testing by thousands ofcycles of load application and release to load supporting constructionsof this design that the cooperating resilient material and internal loadsupporting structure provides a construction with excellent durability,particularly for vehicle seats. Furthermore, the design of the presentinvention permits controlled consistency in the finished product whichis essential for manufacture needs. The design of the present inventionalso permits a comfortable, pleasant supporting seat for a person usingthe structure.

The seat construction shown in FIGURE 1 and generally indicated by theletter A comprises a base portion 1 and a back portion 2 for supportingthe buttocks and back of the passenger respectively. The internal loadsupporting structure of the respective base and back portions of theseat shown in FIGURE 1 are illustrated with somewhat differentconstruction, but it is to be understood that both the back and baseportions could utilize the same internal structure depending on the useand needs of the particular seat. Regarding the base portion internalstructure, more clearly shown in FIGURE 2, the main or sub-base member 3has supported therefrom bolster frame means 4 and mounting frame means 5upon which is mounted load transfer means generally indicated as 6. Theinternal load supporting structure is surrounded by resilient materialgenerally indicated as 7 which is bonded thereto. A suitable covering orupholstery material 8 is secured tightly around the resilient materialfor a finished load supporting structure. The main or subframe 3 can bemade from flat steel, angle iron, or tubular material and is generallyrectangular in shape.

The corresponding back internal load supporting structures of FIGURES 1and utilizes a main or subframe 10 which has mounted thereon mountingmeans 11 which supports load transfer means generally indicated as 12.As in the corresponding seat base structure, the frame 10 of the backcan be made from flat steel, angle iron, or tubular material, and theframe and load transfer means are surrounded by resilient material 7bonded thereto. The resilient material 7 is a foam material, preferablypolyurethane foam, or other similar elastomeric or rubber-like foamedmaterial which can be bonded or secured to the frame members and loadtransfer means.

In the seat construction of FIGURES 1-3, the rigid subframe 3 provides abase to which is secured the end portions 16 of the bolster frame 4 andthe end portions 18 of the mounting frame 5. In the embodiment of FIG.2, the ends 16 and 18 of bolster frame 4 and the mounting frame 5respectively are arranged in overlying relationship, that is, one of theends is placed on the other. Ends 16 and 18 are press-fitted into slotprovided in sub-frame 3. Securing means 15 in the form of a slot areprovided for receiving the end portions 16 and 18, but other suitablesecuring means such as welds, rivets, etc. may be used. The bolsterframe 4 extends from its point of attachment to the subframe 3 in aplane upwardly inclined from the plane of the subframe 3 so that themajor portion of the bolster frame is vertically offset from the planeof the subframe. This offset structural relation of the bolster frame 4to the subframe 3 is important for the purposes of providing a flexiblesoft feel to the user of the seat base as will be discussed in detailhereinafter. The mounting frame 5, as shown in FIG- URES 1-3, consistsof two members 5a and 5b, each extending from its point of attachmentwith the subframe securing means or slot 15 in a U-shaped bend 19 andthereafter extending generally longitudinally and laterally offset fromboth the subframe 3 and the bolster frame 4. In the embodiment ofFIGURES 2 and 3, the mounting frame is connected at its forward end tothe bolster frame 4. The inner connection of the bolster frame 4 andmounting frame 5 unitizes the internal load supporting structure,providing uniform feel and load supporting capabilities for the entireseat base. The load transfer means 6a and 6b are mounted respectively onmounting frame members 5a and 5b and extend generally transverselytowards each other, but terminating in spaced relation to one another atthe central area of the seat. The opposing load transfer means 6a and 6bare interconnected by resilient means 20, preferably rubber bands orstrips, which tend to unitize the central load bearing supportingstructure While permitting a desired degree of flexibility within thecentral area of the structure. The load transfer means 6a and 6b asillustrated, have a plurality of fingers connected by a common back orbank 22, but it is to be understood that the load transfer means couldconsist of individual fingers separately mounted to the mounting frame 5or in pairs, etc., whatever the particular design needs require. Asillustrated, the embodiments of FIGURES 2 and 3 utilizes resilient means21 for interconnecting the rear load transfer means 23 and the subframe3 and interconnecting means 24 is utilized between the bolster andmounting frames; the aforementioned interconnecting means 21 and 24 arefor the purpose of unitizing the internal load supporting structure. Theresilient means 21 is separate from the aforementioned resilient meansbetween opposed fingers, and as illustrated, resilient means 21 ismounted 4 at one end to the unsupported end of the finger 23 adjacentsub-frame 3 (see FIG. 2).

The modified seat base internal supporting structure of FIGURE 4utilizes a sub-base 30 and bolster frame 31 similar to that structure ofthe seat base of FIGURES 2 and 3. However, mounting frame 32 is notinterconnected with the bolster frame 31, but is mounted from thesubframe 30 in cantilevered fashion so that the front portion of themounting frame 32 is unsupported. Both the bent-over ends 33 and 34 ofthe respective bolster frame 31 and mounting frame 32 are positionedadjacent each other and are received in a groove or opening 35 of thesubframe 30. The end portions 34 of the mounting frame 32 extendvertically or at a substantial angle from the openings 35, and areprovided with a vertical arcuate configuration or portion adjacent theopenings 35 as seen in FIGURE 4. The arcuate portions are necessary torelieve stress concentrations in the end portions upon normal loading ofthe support structure. It has been found that providing such an arcuateportion in the mounting frame adjacent each opening 35 of the subframe30 is necessary to prevent undesired fatiguing of the mounting frame atthe junction of its end portion 34 with the remainder of the mountingframe which lies generally parallel to the plane of the subframe 30. Themodified design of FIGURE 4 is particularly adaptable in structuresrequiring a softer feel at the front portion of the structure; the softfeel of the structure made with an internal load supporting structure ofFIGURE 4 is brought about by the cantilevered mountings of bolster frame31 and mounting frame 32 from subframe 30 wherein the bolster frame andmounting frame front portions are free to move downwardly towards theplane of the subframe upon loading in the front or central area. As inthe structure of FIGURES 2 and 3, the opposing load transfer meansgenerally indicated as 36 are interconnected by resilient means 37 whichmay take the form of rubber bands. The load transfer means 36 areillustrated as being joined by a common bank at their common rearportions, but it is to be understood that the load transfer means couldbe made of a plurality of spaced singular elements or any combination ofelements depending on the design and production needs.

FIGURE 5 illustrates the seat back internal load supporting structure ofFIGURE 1. The subframe 10 is provided with mounting slots 13 forreceiving the end portions of mounting frames 11. The mounting frames 11support the load transfer means generally indicated as 12 in the samemanner as in the seat base structures previously described. The opposingload transfer means terminate in spaced relationship to one another andare interconnected by resilient means usually taking the form of rubberbands. In the internal structure arrangement of FIGURE 5 the mountingframes 11 have an interconnecting portion 14 made of the same materialas the mounting frames, for additional securement area to receive thehog-ring or suitable connecting means securing the cover material inplace.

The seat back internal load supporting structure of FIGURE 6 utilizes acantilevered mounting of the mounting frame from the sub-frame 51. Thispermits the unsupported upper end 52 of the mounting frame 50 to moverelative to the subframe 51 in the upper region of the seat frame andprovides a soft feel for the user in this area. In the illustratedembodiment of FIGURE 6, the load transfer means takes the form of bands55 mounted at their respective ends to the mounting frame 50.

The seat back construction illustrated in FIGURE 7 utilizes a bolsterframe in conjunction with the mounting frame and load transfer meanssimilar to that of the seat base structure of FIGURE 4. The bolsterframe 61 is mounted from the subframe in cantilevered fashion so thatthe upper portion 62 of the bolster frame 61 is vertically spaced fromthe subframe permitting relative movement thereto upon loading of theseat back in its upper portion. The mounting frame 65 is secured to thesubframe 60 at 68 and extends generally longitudinally of the seat backstructure in a U-shaped configuration. Mounted from the lateral sides ofthe mounting frames 65 are load transfer means 67 in the form offingers" or elements, having a common base or back portion 69 mounted onthe said mounting frame. It is to be understood that the load transfermeans 67 could take the from of singular ele ts mounted from themounting frame means 65 or in combination of two or three elementsjoined together and mounted from the mounting frame 65. The opposingload transfer means 67 have their unsupported ends interconnected byresilient means 66 usually in the form of rubber bands. In the backinternal structure illustrated, the bolster and mounting frame means areinterconnected by resilient means 70.

In all of the seat base and back constructions of FIG- URES l-7, themounting frame means plays a dual function in (1) supporting the loadtransfer means, and (2) receiving attaching means for securing theupholstery or cover material 8 in place in the finished seat structure,As most clearly shown in FIGURE 1, the cover or upholstery material 8 issecured to the mounting frame by means of a hog ring connection 9 orother suitable connecting means. Securement of the cover to the internalload supporting structure in the manner described is particularlydesirable for mass production since it permits a rapid and effectivemeans for securing the cover in place.

The structures of the present invention provide an unexpected resilipntor soft" feel to the user because of their strcutural arrangementwherein the mounting frame is offset from the corresponding portions ofthe bolster and subframe for relative movement thereto. The seat baseand back structures of the present invention are readily adaptable to bemade firm or solid in selected portions by the use of bands extendingtransversely and mounted at their opposite ends to the mounting frame asin the FIGURE 6 structure. Utilization of such transverse bands can bein conjunction with oppositely facing, split finger" type of loadtransfer means as in FIGURES 1-5 and 7, and would not detract from theover-all comfort of the structures because the mounting frame wouldprovide the desired resiliency by its ability to move relative thebolster and subframes within the surrounding elastomeric foamedmaterial. The versatility of the structures of the present inventionlend them to adaptation to many designs in addition to thoseillustrated, including bench type and support structures.

The structures made in accordance with the present invention have shownunexpected durability in thorough testing programs. The structuresdescribed have excellent characteristics of comfort and a pleasant feelto the person sitting on the structure. The unexpected performance ofthe simple load supporting structure made in accordance with the presentinvention make them highly desirable structures for use in massproduction of load supporting units because of their durability, longlife, comfort and flexibility of design. The basic combination of thestructures with foamed resilient material in surrounding relationship tointernal support and frame members is readily adaptable to many sizesand shapes of loads supporting structures.

While the present invention has been described for particular use withinthe base and back portions of a seat, it is to be understood that theinvention could be utilized in other structures as bench-type seat oftenutilized in the rear seat of an automobile. It is also to be understoodthat the preferred embodiments of the present invention have beendescribed herein in great detail and that certain modifications andchanges may be made by those skilled in the art to which it relates andit is intended to cover hereby all changes, adaptations, andmodifications falling within the scope of the appended claims.

Having described our invention, we claim:

1. Load supporting structure comprising:

frame means including a rigid subframe, and a bolster frame and mountingframe both secured to said subframe,

at least one of said bolster and mounting frames having portions spacedfrom at least a portion of the subframe and movable relative to saidsubframe upon application of load,

load transfer means supported by said mounting frame,

elastomeric material surrounding said mounting frame and said loadtransfer means and bonded to at least [the underside] a portion of saidmounting frame and said load transfer means,

said elastomeric material, load transfer means and said bolster andmounting frames cooperatively transferring any load on said structure tosaid subframe.

2. The load supporting structure as set forth in claim 1 wherein:

said bolster and mounting frames are supported solely at one end to saidsubframe in cantilevered fashion.

3. The load supporting structure as set forth in claim 1 wherein:

said load transfer means is composed of first and second portionssupported solely at one end to opposite sides of said mounting frame andextending transversely towards each other and terminating in spacedrelation to one another in the same plane.

4. The load supporting structure as set forth in claim 3 wherein:

both of said first and second load transfer means portions include aplurality of spaced elements, the unsupported ends of which areinterconnected by resilient means. 5. A load supporting structurecomprising: frame means including a rigid subframe and a mounting framesecured in a flexible manner to said subframe for relative movementthereto upon application of load, said mounting frame secured withinsaid subframe with portions of said mounting frame being inwardly offsetfrom the corresponding portions of said subframe, load transfer meanssupported on said mounting frame, elastomeric material surrounding saidmounting frame and said load transfer means and bonded to at least [theunderside] a portion of said mounting frame and said load transfermeans, said elastomeric material, load transfer means, and said mountingframe cooperatively transferring any load on said structure to saidsubframe. 6. The load supporting structure as set forth in claim 5wherein:

said load transfer means is composed of first and second portionssupported solely at one end to said mounting frame at opposite sides ofsaid structure and extending towards each other and terminating inspaced relation to one another in the same plane. 7. The load supportingstructure as set forth in claim 6 wherein:

both of said first and second load transfer means portions include a setof spaced elements, the unsupported ends of which are interconnected byresilient means. 8. The load supporting structure as set forth in claim5 wherein:

said mounting frame is supported solely at one end to said subframe incantilevered fashion. 9. The load supporting structure as set forth inclaim 8 wherein:

said frame means includes a bolster frame supported solely at one end tosaid subframe in cantilevered fashion and having its major portionoffset from said subframe.

10. In a seat construction, base and back sections each having framemeans including a rigid subframe and a mounting frame secured to thesubframe,

said mounting frame having portions inwardly spaced from said subframe,

load transfer means supported by said mounting frame,

elastomeric material surrounding said mounting frame and said loadtransfer means and bonded to at least [the underside] a portion of saidmounting frame and said load transfer means,

said elastomeric material, load transfer means, and said mounting framecooperatively transferring any load on said structure to said subframe.

11. In a seat construction according to claim 10 in which:

said mounting frame is supported solely at one end to said subframe incantilevered fashion.

12. In a seat construction according to claim 11 in which:

the base and back frame means include a bolster frame secured to andhaving its major portion offset from the plane of said subframe.

13. In a seat construction according to claim 10 in which:

said load transfer means is composed of first and second portionssupported solely at one end to said mounting frame at opposite sides ofsaid structure and extending towards each other and terminating inspaced relation to one another in the same plane.

14. In a load supporting structure as set forth in claim 1 wherein:

end portions of said bolster and mounting frames are positioned adjacenteach other within an opening of said rigid subframe for securing saidbolster and mounting frames to said rigid subframe.

15. In a load supporting structure as set forth in claim 14 wherein:

said end portions extend vertically at a substantial angle to the planeof said rigid subframe.

16. In a load supporting structure as set forth in claim 14 wherein:

a portion of said mounting frame end portions adjacent said openingextend vertically in arcuate configuration to relieve stressconcentrations in said end portions upon loading of said structure.

17. The load supporting structure as set forth in claim 1 wherein:

the major portion of said mounting frame is spaced from said sub-frameand bolster frame, and means inter-connect the spaced portions of saidbolster frame and mounting frame.

18. The load supporting structure as set forth in claim 1 wherein:

said elastomeric material surrounds said frame means and is shaped tothe desired form of the structure, said structure is covered byupholstery material which is secured to said mounting frame by meansextending through said elastomeric material.

19. In the seat construction according to claim 10 in which:

said elastomeric material surrounds said mounting frame and is contouredto conform to the desired seat configuration having a centrally locateddepressed area generally conforming to the human anatomy, said mountingframe being coextensive with the periphery of said depressed area, saidelastomeric material covered by selected upholstery material, and meanssecuring said upholstery material to said mounting frame through saidelastomeric material. 20. A load supporting structure comprising: framemeans including a rigid subframe and a mounting frame secured in aflexible manner to said subframe for relative movement thereto uponapplication of load,

load transfer means supported on said mounting frame,

elastomeric material surrounding said mounting frame and said loadtransfer means and bonded to at least a portion of said mounting frameand said load transfer means,

said elastomeric material, load transfer means and said mounting framecooperatively transferring any load on said structure to said subframe.

21. The invention of claim 20 wherein said elastomeric material isbonded to at least the underside of said load transfer means.

References Cited The following references, cited by the Examiner, are ofrecord in the patented file of this patent or the original patent.

UNITED STATES PATENTS 3,081,077 3/1963 Sudman 267-111 3,084,980 4/1963Lawson 297-455 3,112,987 12/1963 Griffiths 264- 3,140,084 7/1964 Lawson267111 3,208,085 9/1965 Grimshaw 5-345 3,235,245 2/1966 Castelet 267-1033,252,735 7/1966 Smith 297-452 3,259,435 7/1966 Jordan 297-455 3,264,0348/1966 Lawson 297-456 3,266,844 8/1966 Amstutz 297-452 CASMIR A.NUNBERG, Primary Examiner US. Cl. X.R. 297-458

1. LOAD SUPPORTING STRUCTURE COMPRISING: FRAME MEANS INCLUDING A RIGIDSUBFRAME, AND A BOLSTER FRAME AND MOUNTING FRAME BOTH SECURED TO SAIDSUBFRAME, AT LEAST ONE OF SAID BOLSTER AND MOUNTING FRAMES HAVINGPORTIONS SPACED FROM AT LEAST A PORTION OF THE SUBFRAME AND MOVABLERELATIVE TO SAID SUBFRAME UPON APPLICATION OF LOAD, LOAD TRANSFER MEANSSUPPORTED BY SAID MOUNTING FRAME, ELASTOMERIC MATERIAL SURROUNDING SAIDMOUNTING FRAME AND SAID LOAD TRANSFER MEANS AND BONDED TO AT LEAST (THUSUNDERSIDE) A PORTION OF SAID MOUNTING FRAME AND SAID LOAD TRANSFERMEANS,